Extrusion Manufacturing Process Engineer

POSITION TITLE: Extrusion Manufacturing Process Engineer

POSITION OBJECTIVE:

Extrusion Manufacturing Process Engineer (EMPE) position will design and develop manufacturing processes, tooling, and fixtures to meet daily production schedules while enhancing productivity, efficiency, and product quality. Position will lead development and manufacturing trials to access opportunities and manage resources, enabling upgrades to the Extrusion Lines. This includes managing capital improvements, operation, and troubleshooting of system designed to produce fiber optic products. The EMPE will work closely with all functions to ensure high quality, efficient material development, sample qualification, and production.

POSITION RESPONSIBILITIES:

Line and Project Management

• Supervise, schedule, and control the tasks of the Extrusion area
• Effectively manage the full life cycle of operation to include start-up, shutdown, and changeover of extrusion lines.
• Assign and supervise preventive maintenance of tools and equipment.
• Maintain tooling and consumable inventory essential to the extrusion process.
• Assist in capacity planning by considering line speeds, scheduled production runs, and ongoing projects.
• Assist and lead production with various types of equipment and process.
• Review work orders, specifications, or instructions to determine materials, procedures, components, settings, and adjustments for production.
• Develop, manage and implement process/equipment improvement projects.
• Prepare and present detailed plans necessary to complete assigned projects.
• Manage raw materials, planning, schedule/milestones, resources, facilities, and Verification/Validation for assigned projects.
• Coordinates the manufacturing launch of new/revised products including establishing goals, training team members and evaluating results.
• Work with outside vendors to develop tooling, fixtures, and equipment that result in producing high quality product.
• Conduct feasibility studies and analyze data to support project scheduling and execution.
• Act as the liaison between Product Management, Engineering, and Operations.

Continuous Improvement

• Support a continuous improvement and change management mindset.
• Assesses and manages waste, plans/implements efficient production lot sizes to minimize raw material scrap and align raw material lot sizes with finished good production quantity.
• Designs, develops, sources tooling, implements, and tests machinery or equipment for recommended manufacturing methods and line improvements while providing ROI analysis.
• Performs product/process analysis for production and quality metrics.
• Assists in improving the system of production controls, standard operating procedures, safety, quality control, and training.
• Write engineering change orders to process changes to manufacturing documents, drawings, and Bill of Materials.
• Develop processes to ensure repeatability and ensure product meets design requirements.
• Generate documentation on extrusion runs that is used to control traceability and ensure reproducibility.
• Write and execute process and equipment validations (IQ/OQ/PQ).
• Monitors, tracks, and reports key reliability and machine efficiency metrics to identify opportunities for equipment and process improvements.
• Leads the development of corrective actions and problem solving for issues related to reliability and efficiency.
• Develop and maintain equipment criticality assessments and the effective use of maintenance strategies and technologies to protect the business from unplanned failures.
• Maintain compliance with Engineering Standards.
• Support all Company initiatives as identified by management and in support of the Quality Management Systems (QMS), Environmental Management Systems (EMS), and other regulatory requirements.

Extrusion Support

• Adjust machine components to regulate speeds, pressures, temperatures, amounts, dimensions, and flow of materials.
• Examine, measure, and weigh materials or products to verify conformance to standards, using measuring devices such as templates, micrometers, or scales.
• Monitor machine operations and observe lights and gauges to detect malfunctions.
• Clear jams and remove defective or substandard materials or products.
• Move materials, supplies, components, and finished products between storage and work areas, using work aids such as racks, hoists, and hand trucks.
• Select and install machine components, such as dies, molds, and cutters, according to specifications, using hand tools and measuring devices.
• Execute quality checks, cleaning, purging, and maintenance of machinery.
• Manage raw extrusion materials in a way that ensures traceability and prevents contamination.
• Follow established procedures to maintain a clean and organized environment.
• Works safely, practicing, and promoting safety consciousness.
• Supervise, schedule, and control the tasks of the Extrusion area

To perform all other duties assigned or apparent.

COMPETENCIES:

Resilience- Staying energized, productive and focused in the face of challenges, ambiguity, change or strenuous demands, creating a supportive environment that helps others become more resilient and productive.

• Remains focused and productive in the face of difficult or demanding situations such as pervasive ambiguity, frequent change, or high workloads.
• Describes disruptions as challenges that can be overcome rather than threats.
• Adjusts personal coping mechanisms to deal with disruptions.

Initiative- Dealing with situations and issues proactively and persistently, seizing opportunities that arise.

• Acts on opportunities to improve organizational processes or outcomes.
• Perseveres in seeking solutions to complex issues despite significant and ongoing obstacles.
• Creates opportunities to undertake initiatives that will benefit the organization in the near or intermediate term.

Continuous Learning- Identifying and addressing learning and developmental needs to enhance own performance.

• Stays abreast of emerging trends in own area, identifying emerging new requirements.
• Pursues challenging experiences beyond customary role or area of expertise to add value in current area.
• Undertakes learning activities that, while not obviously linked to current position, ultimately provide contacts and content that will impact significantly on current work.

Analytical Thinking- Analyzing and synthesizing information to understand issues, identify options, and support sound decision making.

• Analyzes complex situations, breaking each into its constituent parts.
• Evaluates alternative causes or ways of interpreting complex information.
• Identifies connections between situations that are not obviously related.
• Identifies gaps in information and makes assumptions in order to continue the analysis and/or take action.

POSITION REQUIREMENTS:

• Bachelor’s degree in engineering or science discipline.
• Experience in Programmable Logic Controller (PLC) programing.
• Minimum of 3 years’ experience in process engineering preferred.
• Minimum of 3 years’ experience in polymer extrusion preferred.
• Minimum of 1 year of experience in product and process failure analysis.
• Experience in project management preferred.
• Self-starter with ability to effectively utilize existing resources to solve problems
• Proven ability to implement change through Continuous Improvement
• Experience in extrusion, tooling, troubleshooting equipment, and performing machine and process set-ups
• Experience in Manufacturing Practices (MP), ISO 9001 preferred
• Strong Mechanical aptitude
• Proficient computer, data analysis, and report writing skills
• Detailed oriented mindset
• Hands-on experience of operating extruders with a strong understanding of plastics extrusion processes and downstream equipment, particularly in the context of manufacturing tight-specification products.
• Proficiency in extrusion process optimization, troubleshooting, and equipment setup and maintenance.
• Knowledge of various extrusion materials, including polymers and additives, and their properties.
• Experience with process monitoring and control, statistical process control (SPC), and quality assurance techniques.
• Proven ability to drive improvements in safety, quality, and productivity.
• Ability to differentiate between colored wires, tabs, and electronic components.
• A track record of developing quality products.
• Ability to work independently and drive projects to completion.
• Problem Solving and Root Cause Analysis mindset.
• Coordination and dexterity to grasp, manipulate, and assemble small objects.
• Able to lift 40 pounds.
• Ability to stand for an extended amount of time.
• Ability to travel domestically and internationally as necessary (approx. 5%).

BENEFITS for full time:

• Comprehensive Medical, Dental, and Vision benefits.
• 100% company paid Short-term and Long-term disability insurance coverage.
• 100% company paid Basic Life and Accidental Death and Dismemberment (AD&D) insurance coverage.
• 100% company paid Business Travel Accident (BTA) insurance.
• 100% company paid Employee Assistance Program (EAP).
• Additional voluntary benefits are offered.
• 401K plan: Maximum match is 4.5% of the first 6% of contribution.
• Employee Stock Purchase Plan:
• Clearfield's Time Off Policy includes Personal Time Off (PTO) beginning at three weeks annually. PTO is accrued on the first of the month starting on day of hire. In addition, nine paid holidays per year.

SALARY RANGE: $71,862-$89,828-$107,793, bonus eligible